AirSep Freestyle Service Manual

FreeStyle™ Portable Oxygen Concentrator Service Manual AirSep Corporation • 401 Creekside

AirSep Corp. — FreeStyle Service Manual 1-4 1.4 FreeStyle Product Limited Warranty AirSep Corporation warrants the FreeStyle Oxygen Concentrator

AirSep Corp. — FreeStyle Service Manual 1-5 1.5 FreeStyle Specifications Max Operational Altitude: up to 12,000

AirSep Corp. — FreeStyle Service Manual 1-6 1.6 FreeStyle Classifications Classification Type of protection against electric shock: Class II

AirSep Corp. — FreeStyle Service Manual 2-1 2.0 Operation Check and Test of Oxygen Concentration 2.1

AirSep Corp. — FreeStyle Service Manual 2-2 2 22 2.3 Alarm System An audible alarm sounds if FreeStyle has a low battery, senses no inspi

AirSep Corp. — FreeStyle Service Manual 2-3 2.3.5 Battery Charging To check the level of charge of th

AirSep Corp. — FreeStyle Service Manual 2-4 2 22 2.3.6 Battery Fully Charged When FreeStyle is connected to an AC or DC outlet and is eithe

AirSep Corp. — FreeStyle Service Manual 2-5 2.4 Oxygen Concentration Test and Specification To ensure that FreeStyle’s oxygen output

AirSep Corp. — FreeStyle Service Manual 3-1 3.0 Patient Instructions 3.1 General Instructions It is important that patients thoroughly under

Expedited Product Warranty Check service is always at your fingertips with AirSep: Type www.airsep.info/warranty_check/main.asp OR In the US or Cana

AirSep Corp. — FreeStyle Service Manual 3-2 To charge the AirBelt battery: 1) Release safetycap from end of the AirBelt cord. 2) Connect the

AirSep Corp. — FreeStyle Service Manual 3-3 Depending upon the temperature of the AirBelt battery, it can take several minutes for the charging

AirSep Corp. — FreeStyle Service Manual 3-4 3.2 Routine Maintenance by the Patient To ensure accurate output and efficient operation of the uni

AirSep Corp. — FreeStyle Service Manual 3-5 3.2.2 Alarm/Service Indicator When the unit has reached 5,000 hours of use, a yellow LED will illumin

AirSep Corp. — FreeStyle Service Manual 4-1 4.0 Equipment Provider Maintenance 4.1 No Scheduled Maintenance FreeStyle model units are maintenance

AirSep Corp. — FreeStyle Service Manual 4-2 4.1.3 Compressor Servicing As the Equipment Provider, you are responsible for monitoring the life of

5-1 AirSep Corp. — FreeStyle Service Manual Clean or replace the air intake / gross particle filter with warm soapy water between each patient’s use.

AirSep Corp. — FreeStyle Service Manual 5-2 5.2 Housing Removal 5.2.1 Removing Front Cover 1. Place unit on its back and position the outle

AirSep Corp. — FreeStyle Service Manual 5-3 5.3 Internal Battery Replacement When removing the front cover to remove the battery, always use

Table of Contents Section 1.0 Introduction Section 2.0 Operation Check and 1.1 Equipment Provider Responsibility

5-4 AirSep Corp. — FreeStyle Service Manual 5.4 PSA Removal 1. Disconnect the FreeStyle unit from the AC or DC outlet. 2. Remove the fro

AirSep Corp. — FreeStyle Service Manual 5-5 The following two steps (6 and 7) require extreme caution to ensure the black pressure sensor (U3) is

5-6 AirSep Corp. — FreeStyle Service Manual 8. Remove the 8-32 x ¼” black Phillips screws located in the center of outlet nozzle cradle. (Figure

AirSep Corp. — FreeStyle Service Manual 5-7 11. Disconnect the 1/8” OD black tube from the Y-connector or T connector (which is located at the back

5-8 AirSep Corp. — FreeStyle Service Manual 14. Carefully remove the complete PSA assembly from the center housing by pulling it upwards and slippi

AirSep Corp. — FreeStyle Service Manual 5-9 16. Remove the two mounts from the compressor. (See Figure 5.15.) Figure 5.15

5-10 AirSep Corp. — FreeStyle Service Manual 5.5 Compressor Replacement The compressor is the “pump” within the oxygen concentrator that pushe

AirSep Corp. — FreeStyle Service Manual 5-11 4. If either of the two fittings connecting the compressor to the manifold is connected to the compres

5-12 AirSep Corp. — FreeStyle Service Manual 5.5.2 Compressor Assembly Installation To install the new compressor assembly, perform the compres

AirSep Corp. — FreeStyle Service Manual 5-13 5.6 Product Manifold Replacement 1. Remove the PSA system per Section 5.4. 2. Disconnect the

Section 4.0 Equipment Provider Maintenance 3.2.1 Cleaning the Air Intake Gross Particle Filter

5-14 AirSep Corp. — FreeStyle Service Manual Figure 5.21 5. Holding sieve beds in place, gently pull upward on the product manifold to remove.

AirSep Corp. — FreeStyle Service Manual 5-15 4. Carefully disconnect the Molex connector from the circuit board by pulling on the Molex connector, n

5-16 AirSep Corp. — FreeStyle Service Manual Figure 5.23 5. Remove the plugs from the top and bottom of the new adsorbent beds. 6. Place a

AirSep Corp. — FreeStyle Service Manual 5-17 Figure 5.25 10. Reassemble FreeStyle, and leak test at bed connections. 5.9 Feed/Waste Man

5-18 AirSep Corp. — FreeStyle Service Manual 5. Remove feed/waste manifold by pulling upward on the manifold. Both fittings from the manifold to the

AirSep Corp. — FreeStyle Service Manual 5-19 5.11 Hour Meter Functionality General FreeStyle’s hour meter includes two monitoring channels: a hi

5-20 AirSep Corp. — FreeStyle Service Manual 5.11.4 Toggle/Reset Switch This switch toggles the display or resets the maintenance channel depending

AirSep Corp. — FreeStyle Service Manual 5-21 4. Using a small-head Phillips screwdriver remove (2) 2-56 plastic screws. (Figure 5.29) Figure

5-22 AirSep Corp. — FreeStyle Service Manual 2. Remove inlet screen 3. Remove internal battery per Section 5.3 Internal Battery Replacement.

AirSep Corp. — FreeStyle Service Manual 5-23 9. Remove hour meter as per Section 5.12. 10. Remove cannula nozzle tubing by cutting tie-wrap (us

iii – table of contents AirSep Corporation iii – table of contents 5.13 Circuit Board Replacement 5-21 5.14

5-24 AirSep Corp. — FreeStyle Service Manual Figure 5.34 13. Remove main circuit board from center section assembly. (Figure 5.35) Figure

AirSep Corp. — FreeStyle Service Manual 5-25 5.14 Motor Controller Board Replacement 1. Lift the motor controller board from the circuit boa

5-26 AirSep Corp. — FreeStyle Service Manual 4. Following alignment, view the replacement board from the side at an angle to make certain that the p

AirSep Corp. — FreeStyle Service Manual 5-27 5.15 Control Panel/Key pad Replacement 1. Remove the front and rear cover per Section 5.2. 2

5-28 AirSep Corp. — FreeStyle Service Manual 8. Carefully align control/keypad to enclosure recessed control panel area, and press keypad evenly to

AirSep Corp. — FreeStyle Service Manual 5-29 Figure 5.44 11. Insert flex circuit into rib section and connect flex circuit with carbon cont

5-30 AirSep Corp. — FreeStyle Service Manual 12. Insert into J8 Ziff (zero insertion force) connector, making sure that the flex circuit seats int

AirSep Corp. — FreeStyle Service Manual 5-31 5.16 Fan Replacement When replacing the fan, always use and ESD safe work area. Also, use a

5-32 AirSep Corp. — FreeStyle Service Manual 5. When installing the new fan, be sure the arrow on the side of the fan is pointing outwards toward th

6-1 AirSep Corp. — FreeStyle Service Manual 6.0 Pressure Profiles 6.1 Pressure Profile Quadrant The following pressure profiles illustrate the

AirSep Corp. — FreeStyle Service Manual 7-1 7.0 Troubleshooting 7.1 General Troubleshooting Before reviewing the Troubleshooting Chart, the fol

7.2 Troubleshooting Chart Problem Possible Cause Solution Unit does not turn on when connected to AC power power outlet. Wall switch power i

Problem Possible Cause Solution Battery duration is less than per specification. Note: While charging, battery may not initiate a charge. Allo

Problem Possible Cause Solution Oxygen concentration is below specifications in test mode. Unit’s temperature is too high. Blocked air intake or

8-1 AirSep Corp. — FreeStyle Service Manual 8.0 Recommended Tools 8.1 Tools for FreeStyle Service and Maintenance In additional to a pressure te

AirSep Corp. — FreeStyle Service Manual Appendix  Exploded Drawings Figure 1: FreeStyle — Internal Front View Figure 2: FreeStyle — Internal

Figure A.1: Internal Front View AirSep Corp. — FreeStyle Service Manual A-1

Figure A.2: Internal Rear View - Exploded A-2 AirSep Corp. — FreeStyle Servic

ITEM PART NUMBER DESCRIPTION ITEMPART NUMBER DESCRIPTION 1 BE227-1 BEDS, ASSY, MULTIPLE, 1.500” BED OD, ANNULUS, FREESTYLE 10 OR026-1 O-RING, BUNA

Figure A.4: PSA Assembly Feed / Waste A-4 AirSep Corp. — FreeStyle Service Manual

AirSep Corp. — FreeStyle Service Manual 1-1 1.0 Introduction 1.1 Equipment Provider Responsibility All Equipment Providers of the FreeSty

AirSep Corp. — FreeStyle Service Manual 1-2 1.2 Important Notice and Symbol Explanations As you review both the FreeStyle Patient Manual and t

AirSep Corp. — FreeStyle Service Manual 1-3 1.3 Definitions of Symbols Symbols are frequently used on equipment and/or the manual in preference